Phase II Rehabilitation Works C.H.

Machupicchu

Calculation Sheet for Bridge Crane of Powerhouse

QD210/25t

Codigo de Diseno:
Design Code:

CRN

Aprobado por:

Zheng Yan

No. Interno.:
Doc. no.

2010-08-20

Appr.
Chequeado:

Calculation Note

Doc. kind

Zhao Chunfu

2010-08-20

Checked:
Autor:

Clase de Doc:

1007200

Proyecto:
Project

Niu Pengfei

2010-08-20

Phase II Rehabilitation Works C.H.

Machupicchu

Prep.
Departmento
Emisor:

Auxililary Mechanical System

Cliente:
Customer

Resp. dept
Proveedores:

No. de Proyecto:

Suppliers:

Proj. no.
No. de Doc.:
Doc. no.:

A001186

Proveedor /
Supplier
doc. no.:

HEC-MCU00CRN-FC101

r
Lenguaje:
Lang.

en

Indice de
Rev.:
Rev. ind.

Pagina:
Page
No. de p.:
No. of p.

1
13

Revision

Rev.:
0

Date:
2010-08-20

Description:
Initial Release

Creator:

Checked:

Niu Pengfei

Appr.:

Zhao Chunfu

Doc. Status:

Zheng Yan

BPA

Doc. Status
Code

Description

PRE

Preliminary

INF

For Information

BPO

For Review

BPD

For Design

BPA

For Approval

BPE

Issued for Construction

CCO

As Built

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

2
13

Table of contents

1. Overview/ .........................................................................................................4
2 .Reference documents/ ............................................................................4
3. Parameters of bridge crane / ................................................4
4. Calculation of trolley/ ..............................................................................5
4.1 Calculation of lifting mechanism/ ..................................................5
4.1.1 Max. static tension of the cable of main lifting /. 5
4.1.2 Drum speed calculation/. .................................................5
4.1.3 Lifting static power / ................................................................6
4.1.4 Selection of gearbox/ .............................................................6
4.1.5 Selection of Brake/ .................................................................7
4.2 Calculation of mechanism of translation of the trolley /.................7
4.2.1 Static resistance under steady operation/ ..................7
4.2.2 Static power of motor /. .........................................................8
5. Calculation of bridge frame/ ..................................................................8
5.1 Main parameters /.............................................................................8
5.2 Calculation of static stiffness/ ........................................................9
5.3 Calculation of strength / ..................................................................10
5.4 Calculation of stability/ ................................................................10
6. Traveling machanism of the bridge / .................................... 11
6.1 Static resistance under steady operation / ........................... 11
6.2 Static power of motor /............................................................. 11

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

3
13

1.Overview/

This calculation sheet is based on the technical

Machupicchu

requirements and technical parameters of the

bridge-crane of Machupicchu technical

specifications.

2. Reference documents/
HEC-MCU00SCRN-IG101

General drawing of bridge crane

3. Main parameters of bridge crane /

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

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13


Item

Values

Capacity

2100 (KN)

Hook (ascent/descent)

0.2~2m/min

Rated capacity

2100(KN)

0.2~2m/min

2100(KN)

2100(KN)

30(m)

30m

Travel of the hook

Working class

Class A

4 .Calculation of trolley/
4.1 Calculation of lifting mechanism /
4.1.1Max. static tension of the cable of main lifting/

Maximum static tension calculation of the

cable of main lifting is as follows:

PQ

:
P
2100
S max Q
178.6 KN
mx 6 2 0.98
PQ PQ =2100KN

2100
178.6 KN
mx 6 2 0.98
Where: PQ --Lifting loads PQ =2100 KN
m -- Pulley ratiom=6
-- Cable lifting efficiency =0.98
x -- Drum double rope around, x =2
S max

m m =6
=0.98
x x =2
d
d c S max 0.085 178600 35.9mm

The selection of cable diameter d is as follows:

d c S max 0.085 178600 35.9mm

Where: c -- Cable selection factor, c =0.085
The cable of 38NAT619W+FC+1870 is selected
base on the maximum static tension and its diameter.
Where:
38 -- cable diameter (mm)
NAT -- smoothly surfaced steel wire
6X19W -- number of steel core
FC+1870 means fiber core and tensile
strength is 1870Mpa.

c c =0.085

38NAT619WFC+1870
:
38 (mm)
NAT
619W
FC+1870
1870
:891KN
:891/178.6=4.99

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

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13

The breaking force of steel rope is 891KN, so the

safety factor will be 891/178.6=4.99. This calculation
result is meet 5 specified in the specification, and
meets the contract requirement.

4.1.2 Drum speed calculation/

Calculation of drum rotational speed:

nt

mV
6 2

3 . 7 r / min
D O 3 .14 1 .038

nt

mV
6 2

3 . 7 r / min
D O 3 .14 1 .038

VV=2m/min
D0

Where:
V -- Max. lifting speed, 2 m/min
DO -- Loop diameter of the cable

D0 =Dd=100038=1038mm

D -- Drum diameter, D=1000mm

d -- Cable diameter ,d=38mm
DO =Dd=100038=1038mm

D =1000mm
d =38mm

4.1.3 Lifting static power /

:
PQV
2100103 2

82.4KW
PJ
60 1000 60 1000 0.85
, =0.85
:
PJC=Gx PJ =0.882.4=65.92KW

Lifting static power :

PJ

PQV
60 1000

2100103 2
82.4KW
60 1000 0.85

Where:

-- Mechanical transmission efficiency,

=0.85
V -- Lifting speed, V =2 m/min

G,G=0.8
:YZP315S28 Pn =75KW

Primary motor:
PJC=G x PJ =0.882.4=65.92KW
G -- The average coefficient of steady-state,
G=0.8
Type of motor selected: YZP315S2-8
Pn =75KWJC=40% n =739r/min

Check of motor overload:

JC=40% n =739r/min
:
H
2.1
Pd
pJ
82.4 52.4KW
mm
1 3.3
H ,H=2.1
m m=1
m

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

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13

Pd Pn

H
2.1
Pd
pJ
82.4 52.4KW
mm
1 3.3

..

Where:

H -- Compensation voltage and the load factor,

H =2.1
m The number of motor, m =1
m -- Relative maximum torque coefficient
m =3.3
Pd Pn
Based on the above results, the overload of selected
motor meets the requirements.

4.1.4 Selection of gearbox/

Selection of gearbox:
:
: i
n
739

199.7 i =200
i
nt 3.7
i =200,p=75KW, n =739r/min

739

199.7 i Speed ratio

i
nt 3.7
The proximal ratio to 199.7 is taken 200.
Based on i =200, p=75KW, n =739r/min, the
gearbox of No.M4PHT-90-200-24 is selected and
this gearbox meets the design requirements.

:M4PHT9020024,

4.1.5 Selection of brake/

:
M zh K zh M j =1.25772=965 N .m

Selection of brake:

M zh K zh M j =1.25772=965 N .m

Mj

PQ D0

21001038 0.85

Mj
772N m
2mi
2 6 200
Where:

K zh -- Safety factor for the brake , K zh is taken

1.25 when working class for light duty.
-- Mechanical transmission efficiency,
=0.85

PQ D0
2mi

21001038 0.85
772N m
2 6 200

, =0.85
K zh
K zh =1.25
YWZ9400/E121,

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

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13

 M=2(10002000)N.m
M M zh

The brake type YWZ9-400/E121 is selected. The

braking device has double brakes. The total braking
torque M=2x(1000-2000) N m
M M zh , so this braking device meets the design
requirement.

4.2 Calculation of traveling mechanism of the trolley /

4.2.1 Static resistance under steady operation /

Static resistance under steady operation:

F j Fm F p Fw =27181.99+4942.18

F j Fm F p Fw =27181.99+4942.18

0=32124.17N

0=32124.17N

Fm
Fm ( pQ PG ) w = 2100000+371090

Fm - - Friction force
Fm ( pQ PG ) w = 2100000+371090
0.011=27181.99N

0.011=27181.99N
F p

Fp - - Ramp resistance
Fp ( pQ PG )i =2100000+371090

Fp ( pQ PG )i = 2100000+371090

0.002=4942.18N
Fw -- Wind resistance, as for indoor use,

0.002=4942.18N
Fw Fw =0
PQ , PQ =2100000N

So, Fw =0
PQ -- Lifting capability, PQ =2100000N

PG PG =371090N

PG -- Trolley weight PG =371090N

w w =0.011
i i =0.002

w -- Friction coefficient w =0.011

i -- Rampway-related factor i =0.002

4.2.2 Static power of motor /

Static power of motor

PJ

F jV y
1000 m

32124 .17 5
1 .58 KW
60 1000 0 .85 2

Where:
V y -- Trolley speed V y =5 m/min

PJ

F jV y
1000 m

32124 .17 5
1 .58 KW
60 1000 0 .85 2

m Number of motor, m =2
Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

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13

 -- Mechanical transmission efficiency

=0.85

V y V y =5m/min
m m =2
=0.85
P= K d p j =1.21.58=1.896KW

P= K d p j 1.2 1.58 1.896KW

i
i -- Speed ratio
nD 3.14 1380 450 60
nD 3.14 1380 450 60

398.988
i=
398.988

i=
60Vn
60 5 1000
60Vn
60 5 1000
According to PJ and calculated i , the triple PJ i
device of motor, gearbox and brake PK10-RF07- PK10RF07YVPEJ100L14M1J2
YVPEJ-100L1-4-M1-J2 is selected.
P=22.2KW i =370

P=22.2KW speed ratio i =370

5. Calculation of bridge /
5.1 Main parameters /
1. Known values:
Rated lifting capacity 2100KN
Trolley weight 371.09KN
The total weight of main beam, rails, railings
and electrical appliances will be approximate
105KN
Bridges span 12.7m.

1.
2100KN
371.09KN
105KN,
12.7m
2.,
.

2. The following calculation is based on that the

load acts on the center of span. It is safety
calculation.

The outline of main beam is as follows:

The moment of inertiaof main beam is as follows:

2.131010 mm 4
The section modulus of main beam is as follows:

2.1310 mm
7
W =3.210 mm3
10

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

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13

W =3.2107mm3
5.2 Calculation of static stiffness/

Mid-span deflection

PL3 2100000 2 127003 371090 2 127003

Y
48EI x

48 2.06 105 2.13 1010

12mm Y
Where:
PQ - - Lifting capability

PQ 2100000N

PG - - The self - weight of trolley

PG 371090N

:
PL3 2100000 2 12700 3 371090 2 12700 3
Y
48 EI x
48 2 .06 10 5 2 .13 10 10

12 mm Y

PQ , PQ =2100000N
PG PG =371090N

L -- Span. L=12700mm
E --The elasticity modulus of main beam
2
materials, E =206000 N/mm

L L=12700mm
E E =
2

The vertical static stiffness shall be less than L/750

from the standard Lightweight Classification
Group.

206000 N/mm
, L/750

Y L 750 16.9mm Y

Y L 750 16.9mm Y

Based on the above results, the static stiffness

meets the requirements.

5.3 Calculation of strength

The dynamic load factor of lifting load( ):

=1 + 0.7 V = 1 + 0.7 0.034 =1.0238

VV =2/ 60 =0.034m/s

= 1 + 0.7 V = 1 + 0.7 0.034 =1.0238

Where:
V -- Lifting speedV=2/ 60 =0.034 m/s

M max

The max. bending moment in the beam center line.

M max

( PQ / 2 PG / 2) L
4

( PQ / 2 PG / 2) L
4

qL2
=
8

qL2

1.0238

(2100000/ 2 371090/ 2) 12700 8100127002

1.0238

4
8

0.42 1010 N.mm

( 2100000 / 2 371090 / 2) 12700 8100 12700 2

4
8

0.42 1010 N.mm

M 0.42 1010

131.3MPa
W
3.2 10 7

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

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13

 Q345B(ASTM-A242)

345
S
230MPa
n
1.5

M 0.42 1010

157 MPa
W
3.2 10 7
The main beam is made of Q345B(ASTM-A242):

n =1.5

Where: n -- Safety factor n =1.5

S

345

230MPa
n
1.5

Based on the above results, the strength meets the

design requirements.

5.4 Calculation of stability /

The overall stability of the main beam

h 1436

1.795 3
b 800

Where:
a -- In the ratio of height to width
h -- Section height of main beam
b Section width of main beam

h 1436

1.795 3
b 800

h --

It is unnecessary to check its overall stability if

a is less than 3.

6. Traveling machanism of the bridge /

6.1 Static resistance under steady operation /

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

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13

Steady state static resistance

F j Fm F p Fw =16856+5618.70=22474.7N

F j Fm F p Fw =16856+5618.70=22474.7N

Fm -- The friction drag

Fm
Fm ( p Q PG ) w ( 2 1 00000 7 0935 0) 0.006

Fm ( p Q PG ) w ( 2 1 00000 7 0935 0) 0.006

16856 N

F p

16856 N
Fp Rampway resistance

F p ( p Q PG ) i ( 2100000 7093500) 0.002

F p ( p Q PG ) i ( 2100000 7093500) 0.002 5618.7N

5618.7N
Where:
Fw Fw =0
Fw -- Wind resistance, as to indoor use, Fw =0

PQ , PQ =2100000N

PQ -- Lifting weight, PQ =2100000N

PG -- The self-weight of entire trolley, PG =709350N

PG PG =709350N

w w =0.006

i i =0.002

w -- Friction drag factor w =0.006

i -- Ramp-related factor i =0.002

6.2 Static power of motor/

Static power of motor

1 . 2 22474 . 7 15

P
3 . 97 KW
60 1000 m
60 1000 0 . 85 2
K d F jV y

Where:
Kd -- to consideration with the value of power
magnification factor of inertia effect during
start up, Kd=1.2

m -- The number of motor. m =2

K d F jV y
60 1000 m

1 . 2 22474 . 7 15
3 . 97 KW
60 1000 0 . 85 2

Kd
Kd=1.2
m , m =2
V y V y =15m/min

V y -- Bridge translation speed. V y =15 m/min

n D 0 1380 3 . 14 600

173 . 33
60 V
1000 15 / 60
D D =600
n n =1380r/min

Select gearbox:

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

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Doc. no.:

HEC Inc.

1007200
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HEC-MCU00SCRN-FC101
En

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n D 0 1380 3 . 14 600

173 . 33
60 V
1000 15 / 60

i =173.33 P =3.8kw
PK10YVPEJ112M4M1J2
P =24KW i =178.64

Where:

i -- Speed ratio
D -- Wheel diameter. D =600
n Input rotating speed. n =1380 r/min

Based on speed ratio: i =173.33 P =3.8KW

The triple device of motor is selected as follows:
PK10-YVPEJ-112M-4 -M1-J2

P =24KW i= 178.64
Based on the above result, it meets the requirements.

Finished

Doc. kind:

Caculation Note

Project

Phase II Rehabilitation Works C.H. Machupicchu

Title:

Caculation for Bridge Crane of

Powerhouse

Customer

GyM S.A. / EGEMSA

Proj. no.:

A001186

Supplier doc. no.:

Doc. no.:

HEC Inc.

1007200
Lang.:

Rev. Ind.:

Page:

HEC-MCU00SCRN-FC101
En

No. of
pages:

13
13